Insulating Structure

ABSTRACT

An insulating structure comprises two beams ( 70 ), each having a longitudinally extending connecting means ( 90 ) and upper and lower flanges ( 76, 78 ) arranged such that a channel is defined along two opposing sides of the beam ( 70 ) between the connecting means ( 90 ) and the upper and lower flanges ( 76, 78 ); and an elongate body of insulating material ( 72 ); wherein a first side of the body is engaged along the length of one of the beams ( 70 ) in one of the channels thereof and an opposite second side of the body ( 72 ) is engaged along the length of the other of the beams ( 70 ) in one of the channels thereof.

FIELD OF THE INVENTION

This invention relates to an insulating structure, preferably an insulated beam construction. Particularly, but not exclusively, the invention relates to an insulated beam construction that is suitable for new build ‘room-in-the-roof’ constructions and/or structural walls and flooring.

It will be understood that throughout this application the term ‘beam’ is used generally to denote an elongate load-bearing structure. In use, the beam may be elongate along any axis and may, for example, be vertical, horizontal or inclined. Accordingly, in certain applications, the beam may be considered a rail, a joist or a rafter but is not limited thereto. In addition, the term ‘beam’ need not refer to an integral structure but may relate to a structure formed from a number of discrete parts.

With new build ‘room-in-the-roof’ constructions, it is desirable that certain requirements are met, these being low cost, rapid on-site installation, no need for highly skilled labour and/or specialized equipment, and the creation of loft space which can be utilized for ‘room-in-the-roof’ instantly or at a later date.

In traditional houses, insulation is provided on the floor of a roof space so as to insulate only the inhabitable rooms of the house and not the uninhabitable space in the roof. In ‘room-in-the-roof’ constructions, the insulation that is normally provided on the roof floor must instead be provided on the roof itself. This ensures the ‘room-in-the-roof’ itself is insulated and therefore meets building standards for a habitable room.

In addition, recent changes to UK building regulations mean that all new houses are required to obtain a Standard Assessment Procedure (SAP) rating for energy efficiency. This rating is dependent on the insulation and air tightness of the house and the efficiency and control of the heating system employed. Accordingly, these factors must be taken into consideration when building new houses.

Another consideration for ‘room-in-the-roof’ constructions is how to obtain the required structural rigidity whilst maximizing useable space. A traditional structure using roof trusses limits the amount of useable roof space. Thus, current ‘room-in-the-roof’ constructions employ a series of spaced sloping rafters braced by a series of purlins.

Present ‘room-in-the-roof’ constructions typically have insulation provided on the outside of the supporting structure, underneath the roof tiles. This maximizes roof space but leads to problems with the fixing of the rafters, through the insulting layer, to counter battens on which the tiles are fixed since a typical insulating layer might be 200 mm thick.

It is therefore an object of the present invention to provide an insulating structure with improved properties, which may be used in such ‘room-in-the-roof’ constructions.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided an insulating structure comprising a beam having a longitudinal support member and upper and lower flanges arranged such that a channel is defined along two opposing sides of the beam between the support member and the upper and lower flanges; and an elongate panel of insulating material; wherein a side of the panel is engaged along the length of the beam in one of the channels thereof.

The present invention enables quick and effective construction of an insulated frame by providing a single structure comprising both a beam and an insulating panel. It allows for multiple structures to be connected together by simply slotting (or bonding) the free longitudinal edge of one panel into the free channel of an adjacent beam, thereby forming a continuous insulating path, minimising cold bridging. Thus, the steps of creating a structural frame and then insulating it are combined into a single procedure. The cooperative design of the beam and panel can permit a snug fit between the two elements to improve the integrity of the structure. The incorporation of the panels between the upper and lower flanges of the beams eliminates the risk of gaps appearing between the beams and the panels and results in a much more effective insulating barrier. The structure of the present invention can be quickly and easily assembled either on or off site and can be easily transported if necessary.

The panel may be arranged to completely or substantially completely fill the channel between the upper and lower flanges of the beam. Alternatively, the panel may be arranged to partially fill the channel between the upper and lower flanges of the beam. Preferably, the panel fills at least 50% of the channel between the upper the lower flanges of the beam.

The upper and lower flanges may be of a substantially similar shape.

The upper and lower flanges may be provided in opposite orientations relative to the support member so as to form a beam with a longitudinal axis of symmetry.

The upper and lower flanges may extend generally perpendicularly to the support member.

The upper and lower flanges may be made from timber, metal, plastic, concrete or any other structural material.

In a particular embodiment of the first aspect of the invention, the upper and lower flanges each comprise an elongate rectangular block with a longitudinal recess provided in one face thereof, and the support member is arranged to extend between the recess in the upper flange and the recess in the lower flange.

Optionally, the support member extends between the centres of the upper and lower flanges.

The support member may comprise insulating material, which may be high-density insulating material, such as polyisocyanurate foam. Alternatively, the support member may be partially or wholly made from plywood, chipboard, block wood, laminated wood, oriented strand board (OSB), metal or plastics material.

The support member may be attached to the upper and lower flanges by an adhesive, for example a polyurethane adhesive. Alternatively, the support member may be mechanically attached to the upper and lower flanges.

Optionally, the beam has a substantially ‘I’ shaped cross-sectional area along its length.

The panel may comprise polyisocyanurate foam, polystyrene, phenolic foam, mineral wool or any other insulating material.

In a particular embodiment, the panel and the support member are combined in a single component. Alternatively, the panel is bonded to the support member by an adhesive. The panel may also be bonded to the upper and/or lower flanges by an adhesive.

The Applicants have demonstrated that by adhering the panel to the beam, the structural performance of the insulating structure is significantly greater than that which would be expected for the combination of the individual components without glue. Accordingly, this embodiment of the present invention may permit a reduction in the number of beams required to provide a roof, wall or floor structure of a predetermined strength.

The longitudinal support member may be continuous or discontinuous along the length of the beam.

According to a second aspect of the present invention there is provided a beam comprising a longitudinal support member of insulating material having respective upper and lower flanges along its longitudinally extending upper and lower sides, the support member serving to interconnect the upper and lower flanges, and either being the sole interconnection between the flanges or any other interconnection being of only relatively short longitudinal extent along the beam.

The advantage of the above is that the insulating material provides a thermal break between the upper and lower flanges. If other interconnections are provided, these may create a thermal bridge between the upper and lower flanges. However, by limiting any other interconnection to be of only a relatively short longitudinal extent along the beam, the effects of any resulting thermal bridge can be minimized.

Preferably any other interconnection has a maximum extent of 50% of the length of the beam, more preferably 40%, even more preferably 30%, still more preferably 20% and even more preferably 10%.

The support member may be made of polyisocyanurate foam. Alternatively it may be partially made from plywood, chipboard, block wood, laminated wood, oriented strand board (OSB), metal or plastics material. The beam is preferably of I-shape in cross-section, and the flanges are desirably of timber, metal, plastic, concrete or any other structural material.

The support member may be continuous or discontinuous along the length of the beam.

According to a third aspect of the present invention there is provided an insulating structure comprising an elongated panel of insulating material, upper and lower flanges of a beam engaging respective opposite surfaces of the panel, and fixing means of the beam extending between the upper and lower flanges to secure the flanges together.

The fixing means may pass through the panel to secure the flanges together. Alternatively, the fixing means may lie adjacent to or spaced from an edge of the panel.

Accordingly, the panel may extend from one or both sides of the upper and lower flanges.

The fixing means may comprise a bolt or screw. In one embodiment, respective opposite ends of the panel are formed with the components of a tongue and groove arrangement, whilst in another embodiment one end of the structure defines a channel to receive an opposite end of a further identical structure.

By fitting the free end of the panel of a further identical structure into the ‘open’ channel of the structure of the second aspect of the present invention, or by interlinking such structures by use of the tongues and grooves, there can be formed a continuous insulating path, thereby reducing cold bridging. This, in turn, may allow the thickness of insulating material employed to be reduced. In addition, use of this aspect of the invention negates the need for builders to insulate the structure created (i.e. roof, wall or floor) on site.

According to a fourth aspect of the present invention there is provided an insulating structure comprising two beams, each having a longitudinally extending connecting means and upper and lower flanges arranged such that a channel is defined along two opposing sides of the beam between the connecting means and the upper and lower flanges; and an elongate body of insulating material; wherein a first side of the body is engaged along the length of one of the beams in one of the channels thereof and an opposite second side of the body is engaged along the length of the other of the beams in one of the channels thereof.

In a preferred embodiment fixing means is provided to secure the body of insulating material to each beam. The fixing means is preferably provided between the connecting means and the body. The fixing means may also be provided between the upper and/or lower flanges and the body.

The fixing means is preferably in the form of an adhesive, for example a polyurethane adhesive. Additionally, or alternately, the fixing means may comprise a mechanical fixing such as a screw or nail.

An advantage of the fourth aspect of the invention is that an integral insulated structural unit (i.e. cassette) is provided. This unit is relatively lightweight and easy to fix when compared to existing roof structures since there is no need to attach each of the beams, through a layer of insulating material, to a counter batten. In addition, due to the nature of the structure, a space for accommodating cables, pipes or further insulation is conveniently provided between adjacent beam flanges. It is envisaged that in use, each unit will be joined to the next by providing an individual insulating panel between the free channels of adjacent beams. As the insulating panel in the above unit contributes to the structural properties of the unit, it is possible to provide the same structural support using fewer beams than would be required in conventional constructions (i.e. using the above units a larger spacing between adjacent beams can be accommodated without a reduction in structural integrity). This results in a reduction of costs since insulating panels are cheaper than beams. Also, a construction (i.e. roof, wall or floor) will derive its structural support and insulating properties from an assembly of these units alone. Further advantages of the above are that because each beam in a construction of linked units is held in a fixed relationship with the others, smoother walls can be obtained and the fixing of plasterboard onto the beams is made easier.

Further advantages of the fourth aspect of the present invention are that the structure can be factory insulated, has a high structural strength and rigidity, is airtight, can be rapidly installed with traditional methodology and is substantially waterproof.

Embodiments of this aspect of the present invention can been used to create a roof with sufficient rigidity that purlins are no longer required to brace the structure. The exclusion of purlins is most beneficial and assists the construction process. It also removes the need to provide later fire-protection to the purlins. Furthermore, the installation of dormers and solar panels can be less problematic using the above since two such units can be fitted in place with the required gap in-between for the dormer/solar panel. This gap can then be filled in, when appropriate, with a correspondingly sized body of insulating material between the exposed adjacent channels of each unit.

The insulating body may be a panel of insulating material. Alternatively, the insulating body may be a container filled with insulating material. The insulating material may comprise polyisocyanurate foam, polystyrene, phenolic foam, or mineral wool.

The connecting means may comprise insulating material, which may be high-density insulating material, such as polyisocyanurate foam. Alternatively, the connecting means may be partially or wholly made from plywood, chipboard, block wood, laminated wood, oriented strand board (OSB), metal or plastics material.

The upper and lower flanges may be made from timber, metal, plastic, concrete or any other structural material.

The two beams may be arranged to be substantially parallel when the body of insulating material is engaged in a channel of each beam.

In particular embodiments of the invention, the insulating body may be arranged to maintain a set spacing between the beams.

In another embodiment, the insulating body may be integral with one or more of the longitudinal connecting means.

The connecting means may be continuous or discontinuous along the length of the beam.

In another embodiment of the fourth aspect of the invention, the structure further includes a beam disposed intermediate said two beams, the beam comprising upper and lower flanges engaging respective opposite surfaces of the body and fixing means of the beam extending between the upper and lower flanges to secure the flanges together.

With any of the first, third or fourth aspects of the invention, a layer of insulation may be provided between the underside of the insulating panel and a surface upon which the construction is laid, so as to fill the gap formed between adjacent lower flanges. Optionally, the layer of insulation may be attached to the insulating panel on each structure before the individual structures are connected. The layer of insulation may be configured for thermal and/or acoustic and/or fire insulation.

In any of the above aspects of the invention, the insulating material may be thermally and/or acoustically insulating. Alternatively or additionally, the material may be insulated against fire (i.e. fire resistant).

According to a fifth aspect of the present invention there is provided a roof structure comprising an insulating structure or beam according to any of the above aspects of the invention.

Such a roof may derive enough structural strength and/or rigidity from the insulating structure or beam employed that purlins are no longer necessary.

According to a sixth aspect of the present invention there is provided a building structure comprising an insulating structure or beam according to any one of the above first to fourth aspects of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 shows a perspective view of an insulating structure according to an embodiment of the first aspect of the present invention;

FIG. 2 shows an end view of an insulating construction including two insulating structures according to FIG. 1;

FIG. 3 shows a perspective view of an insulating beam according to an embodiment of the second aspect of the present invention;

FIG. 4 shows a perspective view of part of an insulating structure according to an embodiment of the third aspect of the present invention, but with the insulating panel omitted for clarity;

FIG. 5 shows an end view of an insulating structure according to an embodiment of the third aspect of the present invention;

FIG. 6 shows an end view of an insulating structure according to an alternative embodiment of the third aspect of the present invention;

FIG. 7A shows an end view of an insulating structure according to a first embodiment of the fourth aspect of the present invention;

FIG. 7B shows an end view of an insulating structure according to a second embodiment of the fourth aspect of the present invention;

FIG. 7C shows an end view of an insulating structure according to a third embodiment of the fourth aspect of the present invention;

FIG. 8 shows an end view of a construction including two spaced apart insulating structures according to FIG. 7B, with a further body of insulating material provided therebetween; and

FIG. 9 shows an end view of an insulating structure combining the features of the structure shown in FIG. 7C with the features of the structure shown in FIG. 5.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

With reference to FIG. 1, there is illustrated an insulating structure 10 according to an embodiment of the first aspect of the present invention. This comprises an I-beam 12 and an elongate thermally insulating panel 14. The I-beam 12 comprises a longitudinal support member 16, an upper flange 18, and a lower flange 20. As such, a channel 22 is defined along two opposing sides of the I-beam 12 between the support member 16 and the upper and lower flanges 18, 20. The panel 14 includes an upper surface 28, a lower surface 30 and opposed sides 24 and 25. A side 24 of the panel 14 is engaged along the length of the I-beam 12 in one of the channels 22 thereof, abutting against the support member 16 and the upper and lower flanges 18, 20.

The upper and lower flanges 18, 20 are made from timber and each is formed from an elongate rectangular block with a central longitudinal recess 26 provided in one face thereof. The upper and lower flanges 18, 20 are arranged opposite one another with their respective recesses 26 facing inwardly. The support member 16 is formed from thermally insulating material such as mineral wool, polyisocyanurate or other suitable material, and extends between the recess 26 in the upper flange 18 and the recess 26 in the lower flange 20. An adhesive (not shown) is provided in each recess 26 to bond the support member 16 to the upper and lower flanges 18, 20.

The thermally insulating panel 14 is made from mineral wool, polyisocyanurate or other insulant and is substantially cuboidal in shape. The side 24 of the panel 14, which is engaged in one of the channels 22 of the beam 12, is attached to the support member 16 by an adhesive 17. In this embodiment, the upper surface 28 and lower surface 30 of the panel 14 are also bonded, respectively, to the upper and lower flanges 18, 20.

In this particular embodiment of the invention, the upper and lower flanges 18, 20 have a greater width (w) than depth (d). In addition, the support member 16 has a significantly smaller width (W) than the width (w) of the upper and lower flanges 18, 20. Consequently, the channels 22 are of a reasonable depth (D) in order to provide a ledge 32, on the top surface of the lower flange 20, which is capable of supporting and bearing the weight of the panel 14. The greater the depth (D) of the channel 22, and hence the wider the ledge 32, the more stable the structure 10 is likely to be. Further, the wider the ledge 32, the less likely that the panel 14 will flex due to gravity.

The I-beam 12 and panel 14 may be manufactured separately and brought together to form the structure 10. Alternatively, the support member 16 may be integral with the panel 14. Although, as shown, the member 16 is the sole interconnection between the flanges, in another embodiment, one or more longitudinally very short (relative to the beam length) metal brackets could be provided along the length of the beam, extending between the flanges, to add strength/rigidity to the beam, if required.

The structure 10 of present invention provides for a quick and effective formation of an insulating construction 40, as illustrated in FIG. 2. Here, two identical structures 10 are connected together by slotting the free longitudinal side 25 of the panel 14 of a first structure 10 into the free channel 22 of the I-beam 12 of a second structure 10. Naturally, this process may be repeated as often as necessary in order form the construction required.

A shown in FIG. 2, the construction 40 is formed above a layer of plasterboard 42. In the case where the construction 40 forms a floor in a loft, the plasterboard 42 forms the ceiling of the room below.

In the embodiment shown in FIG. 2, a layer of insulating material in the form of rockwool 44 is provided in the gaps between adjacent lower flanges 20, i.e. between the plasterboard 42 and the lower surface 30 of the insulating panel 14. Conveniently, rockwool 44 provides both acoustic and fire insulation. For ease of application, the layer of rockwool 44 is attached to the insulating panel 14 on each structure 10 before the individual structures 10 are connected.

The advantages of the first aspect of the present invention are that it simplifies and accelerates the process of forming an insulated construction 40. It also ensures a robust and effective insulating barrier, and eliminates considerable waste whilst improving the air tightness and thermal efficiency of a construction.

FIG. 3 shows an embodiment of a beam 46 in accordance with the second aspect of the present invention. The beam 46 comprises a longitudinal support member 48 of insulating material with respective upper and lower flanges 50, 52 along its longitudinally extending upper and lower sides. As for the beams shown in FIGS. 1 and 2, the upper and lower flanges 50, 52 are made from timber and each is formed from an elongate rectangular block with a central longitudinal recess 54 provided in one face thereof. The upper and lower flanges 50, 52 are arranged opposite one another with their respective recesses 54 facing inwardly. The support member 48 is formed from thermally insulating material such as mineral wool, polyisocyanurate or other suitable material, and extends between the recess 54 in the upper flange 50 and the recess 54 in the lower flange 52. An adhesive (not shown) is provided in each recess 54 to bond the support member 48 to the upper and lower flanges 50, 52.

In this embodiment, the longitudinal support member 48 provides the sole connection between the upper and lower flanges 50, 52. Accordingly, the insulating material of the longitudinal support member 48 provides a thermal break between the upper and lower flanges 50, 52.

FIGS. 4 to 6 illustrate embodiments of an insulting structure in accordance with the third aspect of the present invention. In particular, FIG. 4 shows a beam 56 of the insulating structure without an insulating panel as shown in FIGS. 5 and 6, for purposes of clarity.

The beam 56 comprises upper and lower flanges 58, 60 and fixing means 62 extending therebetween to secure the upper and lower flanges 58, 60 together. The upper and lower flanges 58, 60 are each made from timber and are in the form of an elongate rectangular block. The fixing means 62 in this embodiment comprises four screws 64 generally equally spaced along the length of the beam 56. However, the number and distribution of the screws 64 along the beam 56 may be chosen to suit the length and strength requirements of the beam 56.

As shown in FIG. 5, in one embodiment of this aspect of the present invention, the screws 64 extend through the centre of an elongated panel of insulating material 66 such that the panel extends from both sides of the beam 56.

As shown in FIG. 6, in another embodiment of this aspect of the present invention, the screws 64 lie adjacent one side of an elongated panel of insulating material 66 such that the panel extends from only one side of the beam 56.

In either of the above two embodiments multiple insulating structures may be employed adjacent one another to provide an insulated construction. In addition, the panels 66 may be provided with mutually co-operating structures at their free ends (i.e. of a tongue and groove arrangement) so as to easily lock with an adjacent structure.

FIGS. 7A to 7C illustrate embodiments of an insulting structure in accordance with the fourth aspect of the present invention.

Referring to FIG. 7A, an insulting structure 68 comprises two I-beams 70 and an elongate thermally insulating panel 72 extending therebetween. Each I-beam 70 comprises a longitudinal support member 74, an upper flange 76, and a lower flange 78. As such, a channel 80 is defined along two opposing sides of the I-beam 70 between the support member 74 and the upper and lower flanges 76, 78. The panel 72 includes an upper surface 82, a lower surface 84 and opposed sides 86 and 88. One side 86 of the panel 72 is engaged along the length of one I-beam 70 in one of the channels 80 thereof whilst the other side 88 of the panel 72 is engaged along the length of the other I-beam 70 in one of the channels 80 thereof. The panel 72 is glued by an adhesive 90 at each side 86, 88 to a respective longitudinal support member 74.

The upper and lower flanges 76, 78 are each made from timber and formed from an elongate rectangular block with a central longitudinal recess 92 provided in one face thereof. The upper and lower flanges 76, 78 are arranged opposite one another with their respective recesses 92 facing inwardly. In this embodiment, the support member 74 is formed from plywood. However, in other embodiments it may be formed from thermally insulating material such as mineral wool or polyisocyanurate. The support member 74 extends between the recess 92 in the upper flange 76 and the recess 92 in the lower flange 78. An adhesive (not shown) is provided in each recess 92 to bond the support member 74 to the upper and lower flanges 76, 78.

The thermally insulating panel 72 is made from mineral wool, polyisocyanurate or other insulant and is substantially cuboidal in shape.

In the embodiment of FIG. 7A, the panel 72 is attached to each I-beam 70 midway along their respective channels 80. Accordingly, gaps are provided between the upper and lower surfaces 82, 84 of the panel 72 and the upper and lower flanges 76, 78 of the I-beams 70.

FIG. 7B illustrates an embodiment of an insulting structure 94 that is substantially the same as that described above for FIG. 7A and so identical reference numerals are employed. The difference in this insulating structure 94 is that the panel 72 is attached to each I-beam 70 along the lower portions of the respective channels 80. Accordingly, the lower flanges 78 are in contact with the lower surface 84 of the panel 72 and gaps are only provided between the upper surface 82 and the upper flanges 76. Additional adhesive may be provided between the lower flanges 78 and the lower surface 84 of the panel 72, for increased security.

An advantage of this embodiment is that the structure is more stable than that shown in FIG. 7A since forces acting between the lower flanges 78 and the panel 72 can help to maintain the structural integrity of the unit.

FIG. 7C illustrates a further embodiment of an insulting structure 96 that is substantially the same as that described above for FIG. 7B and so, again, identical reference numerals are employed. The difference in this insulating structure 96 is that the panel 72 extends over the whole depth of the channels 80. Accordingly, both the upper and lower flanges 76, 78 are in contact with the, respective, upper and lower surfaces 82, 84 of the panel 72. In this case, additional adhesive may be provided between the upper and lower flanges 76, 78 and the, respective, upper and lower surfaces 82, 84 of the panel 72, for increased security.

An advantage of this embodiment is that the structure is even more stable than that shown in FIG. 7B since forces acting between the upper and lower flanges 76, 78 and the panel 72 can help to maintain the structural integrity of the unit.

FIG. 8 shows an example construction including two spaced apart insulating structures 94 according to FIG. 7B, with a further body of insulating material 98 provided therebetween. The further body of insulating material 98 is of the same thickness as the panels 72 but can be of any width required to fill the gap between adjacent insulating structures 94. As shown in FIG. 8, the further body of insulating material 98 is positioned in the channels 80 of the insulating structures 94 at the same position as the panels 72 (i.e. extending from adjacent the lower flanges 78 with a gap provided below the upper flanges 76. The further body of insulating material 98 is preferably glued to each adjacent longitudinal support member 74.

The two insulating structures 94 (i.e. cassettes) are preferably factory bonded and locked together on-site by bonding in the further body of insulating material 98. The two insulating structures 94 may be fixed to an external structure before the further body of insulating material 98 is inserted. This approach can assist the installation of solar panels, dormers and other similar roof openings such as for velux-type windows, which may be provided in a space between adjacent insulating structures 94. It will also facilitate a later roof panel (i.e. cassette) layout. Conveniently, each cassette is 1200 mm wide and in-fills (i.e. further bodies of insulating material 98) are provided in appropriate sizes to fill any gaps. In addition, this system means that less bonding/fixing is required on site—saving time and cost and reducing the likelihood of human errors and accidents during the construction.

Although, the various aspects described above have involved fixing by glue, other types of fixing means such as silicon bead or mechanical fixings may be employed. It should be noted, however, that the Applicants have found that fixing the panels and I-beams together by glue generally provides the most rigid structure.

In relation to all of the above aspects of the invention, it will be understood that the relative dimensions of each component part of the insulating structures and beams can be varied to suit individual circumstances. For example, the length, height and width of each cassette (i.e. structural unit) of the fourth aspect of the invention may be varied. In particular embodiments the insulating panels May typically have a width of 600 mm to 1200 mm, a length of up to 12 metres and a depth of 150 mm to 300 mm.

It should be noted that traditional I-beams use less material than normal (block) joists and have very good strength capabilities in the vertical direction (i.e. along the vertical axis of the ‘I’). However, traditional I-beams do not have good strength capabilities in the lateral direction and therefore they require stabilization. Solid blocking pieces (often also configured as I-beams) are commonly provided between adjacent I-beams (across the top, middle, bottom) for stability. This construction is time-consuming, awkward, manual and dangerous. In addition the whole structure often also requires bracing with diagonal timber (i.e. purlins). As a result, I-beam roof constructions are not very popular at present.

It should also be noted that wall panels are required to withstand loads in both their vertical and horizontal planes (i.e. due to the weight of a roof acting vertically and the force of wind acting horizontally). Normally, Oriented Strand Board (OSB) or plywood sheathing/facing boards are used to stiffen wall panels and to help prevent lozenging where the wall leans to one end.

Aspects of the present invention address the above problems by providing a more stable, rigid and insulated structure. In particular, embodiments of the fourth aspect of the present invention provide for a panellized insulated I-joist system. Through standard testing mechanisms, the Applicants have shown that such a system has the following advantages. Firstly, bonded insulated I-joist panels (i.e. as shown in FIGS. 7A to 7C) are 3-8% stiffer (i.e. more rigid) that traditional I-joists acting alone. Accordingly, a similar enhancement in roof/wall stiffness may be realized over traditional I-joist designs. Also, a marked enhancement is observed on the strength and stability of the I-joists when subject to loads. Separate, traditional I-joists show a tendency to buckle when deflections exceed 25 mm. However, no such buckling was observed on the insulated panels tested. Important implications of the above are that blocking/bracing requirements are either simplified or completely eliminated. Accordingly, there may be no need for stability noggins to be used with the present panellized construction. Consequently, the system is much quicker and easier to erect than a normal I-joist construction, resulting in lower labour costs for the erection procedure. Furthermore, the present panellized construction is relatively lightweight and therefore easy to handle since the insulating panel itself does not add much to the weight of the structure.

In addition, since the insulating panel in the structure adds approximately 5-10% to the strength of the beams on their own, the span of the panellised structure can be increased by the same factor. Alternatively, the structure may span a longer distance than traditional I-beams, without requiring purlins.

Furthermore, the integrated insulating panel will provide greater insulating properties than traditional loose-fill and other insulating mechanisms. In order to meet insulation requirements it is likely that the insulating panel should fill at least 50% of the height of the channel in each of the beams. Also, a service zone will be conveniently provided at one side of the panel, between adjacent flanges, while a ventilation gap will be provided at the opposite side of the panel.

As described above, non-standard centres between rafters (e.g. around dormers) can be easily catered for via loose cut-to-width insulation sections, which are installed on site between the pre-insulated panels. In addition, structural engineering of the system can be done using conventional principles and published I-joist data so that its use can be easily evaluated.

Overall, the fourth aspect of the present invention provides an I-beam structure in both the vertical and horizontal planes. This leads to increased compression strength in both planes. It has also been found that gluing the sides of the insulating panel to the longitudinal support member of the beam adds to the structural rigidity of the unit, particularly in the lateral plane.

The Applicants have found that the insulated structure of the fourth aspect of the invention is approximately 75% as rigid as a wall fitted with a sheathing board. Consequently, if 75% good enough, there will be no need for a sheathing board at all. Alternatively, the present invention can be used in conjunction with a standard sheathing board to obtain a higher degree of rigidity than normal or it can be used with a thinner or lighter sheathing board to obtain an equivalent rigidity value. Moreover, the present invention can be advantageously used to create cavity walls wherein the cavity is provided to one side of the insulating panel, between adjacent beam flanges.

As a further alternative, discontinuous connecting means (i.e. screws) may form the support member in the beams to reduce the amount of thermal bridging and improve the insulating properties of the structure.

FIG. 9 shows an embodiment of the fourth aspect of the invention based on the embodiment shown in FIG. 7C and so like reference numerals will be employed for like parts. The difference in this insulating structure 100 is that a further beam 102 is disposed intermediate the two end beams 70. The further beam 102 in this embodiment is disposed midway along the width of the panel 72 but it could be provided at any point between the two beams 70. Furthermore, a number of further beams 102 may be provided between the two beams 70. The further beam 102 comprises an upper flange 104 and a lower flange 106 engaging respective opposite surfaces of the panel 72. A fixing means 108 passes through the panel 72 and extends between the upper and lower flanges 104, 106 to secure the flanges together.

It will be appreciated by persons skilled in the art that various modifications may be made to the above-described embodiments without departing from the scope of the present invention. For example, whilst the above discussion has primarily been concerned with the construction of walls, floors and roofs for domestic dwellings, the invention is equally applicable to other types of buildings and constructions. In addition, it will be understood that the various features of the above-described embodiments and different aspects of the invention may be mixed and matched to suit particular applications without departing from the scope of the present invention. 

1-54. (canceled)
 55. An insulating structure comprising: two beams, each having a longitudinally extending connecting means and upper and lower flanges arranged such that a channel is defined along two opposing sides of the beam between the connecting means and the upper and lower flanges; and an elongate body of insulating material; wherein a first side of the body is engaged along the length of one of the beams in one of the channels thereof and an opposite second side of the body is engaged along the length of the other of the beams in one of the channels thereof.
 56. An insulating structure according to claim 55 wherein fixing means is provided to secure the body of insulating material to each beam.
 57. An insulating structure according to claim 56 wherein the fixing means comprises an adhesive.
 58. An insulating structure according to claim 55 wherein the insulating body is a container filled with insulating material.
 59. An insulating structure according to claim 55 wherein the connecting means comprises an insulating material.
 60. An insulating structure according to claim 55 wherein the insulating body is integral with one or more of the longitudinal connecting means.
 61. An insulating structure according to claim 55 further comprising a beam disposed intermediate said two beams, the beam comprising upper and lower flanges engaging respective opposite surfaces of the body and fixing means of the beam extending between the upper and lower flanges to secure the flanges together.
 62. An insulating structure comprising an elongated panel of insulating material, upper and lower flanges of a beam engaging respective opposite surfaces of the panel, and fixing means of the beam extending between the upper and lower flanges to secure the flanges together.
 63. An insulating structure according to claim 62 wherein the fixing means passes through the panel to secure the flanges together.
 64. An insulating structure according to claim 62 wherein the fixing means lies adjacent to or spaced from an edge of the panel.
 65. An insulating structure according to claim 62 wherein the fixing means comprises a bolt or screw.
 66. An insulating structure according to claim 62 wherein respective opposite ends of the panel are formed with the components of a tongue and groove arrangement.
 67. An insulating structure according to claim 62 wherein one end of the structure defines a channel to receive an opposite end of a further identical structure.
 68. An insulating structure comprising a beam having a longitudinal support member and upper and lower flanges arranged such that a channel is defined along two opposing sides of the beam between the support member and the upper and lower flanges; and an elongate panel of insulating material; wherein a side of the panel is engaged along the length of the beam in one of the channels thereof.
 69. An insulating structure according to claim 68 wherein the panel is arranged to completely or substantially completely fill the channel between the upper and lower flanges of the beam.
 70. An insulating structure according to claim 68 wherein the upper and lower flanges each comprise an elongate rectangular block with a longitudinal recess provided in one face thereof, and the support member is arranged to extend between the recess in the upper flange and the recess in the lower flange.
 71. An insulating structure according to claim 68 wherein the support member comprises insulating material.
 72. An insulating structure according to claim 68 wherein the panel and the support member are integral.
 73. An insulating structure according to claim 68 wherein the panel is bonded to the support member by an adhesive.
 74. An insulating structure according to claim 68 wherein the panel is bonded to the upper and/or lower flanges by an adhesive. 